System and method for applying a fastening material to a substrate

ABSTRACT

A system for applying a fastening material to a substrate is provided. The system may include a first material source including the substrate. The substrate may define a first length extending from a first edge to a second edge and the first material source may feed the substrate in a first direction transverse to the first length. The system may additionally include a second material source including the fastening material. The fastening material may define a second length extending from a third edge to a fourth edge, whereby the second length is substantially equal to the first length and the second material source feeds the fastening material in a second direction transverse to the second length. The system may also include an applicator system that secures the fastening material to the substrate.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.62/330,390 filed May 2, 2016, the entirety of which is herebyincorporated herein by reference.

FIELD

The present disclosure relates generally to a system and method forapplying a fastening material to a substrate, and more particularly to asystem and method for applying a re-closable fastening material to apackaging substrate.

BACKGROUND

This section provides background information related to the presentdisclosure and is not necessarily prior art.

Packages and containers, such as bags and pouches, often utilize afastening system disposed along one or more edges of the package toallow an end user to access the package. For example, various foodstuffpackages often utilize a re-closable fastening system disposed along anedge of the package to allow an end user to access and reclose thepackage.

While such fastening systems adequately permit a user to access andreclose a package, application of such fastening systems to a packagecan be time consuming and, as a result, costly. For example, systems andmethods for applying conventional fastening systems to a substrate oftenrequire metering a quantity of fastening material that is equal to alength of the opening in the package. Further, such fastening materialtypically also includes flanges disposed on opposite sides of a workingportion of the fastening system that permits a machine to grip and feedthe fastening material into a desired position during manufacturing ofthe package. The added manufacturing steps and increased materialrequired to form the flanges add to the processing time required tomanufacture the package and, therefore, increase the overall cost of theproduct.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

In one configuration, a system for applying a fastening material to asubstrate is provided. The system may include a first material sourceincluding the substrate. The substrate may define a first lengthextending from a first edge to a second edge and the first materialsource may feed the substrate in a first direction transverse to thefirst length. The system may additionally include a second materialsource including the fastening material. The fastening material maydefine a second length extending from a third edge to a fourth edge,whereby the second length is substantially equal to the first length andthe second material source feeds the fastening material in a seconddirection transverse to the second length. The system may also includean applicator system having a cutting block and a seal head. The cuttingblock may have a cutting mechanism defining a third length substantiallyequal to the first length and the seal head may define a fourth lengthsubstantially equal to the first length. The cutting block and the sealhead may secure the fastening material to the substrate such that thefirst edge is aligned with the third edge and the second edge is alignedwith the fourth edge.

In one configuration, the first material source includes a first axis ofrotation and the second material source includes a second axis ofrotation. The first length may extend in a direction substantiallyparallel to the first axis of rotation and the second length may extendin a direction substantially parallel to the second axis of rotation.

The fastening material may define a width extending in a directionperpendicular to the second length, whereby the width is less than thesecond length. Specifically, the width may be between 1% and 10% of thesecond length.

In one configuration, the fastening material includes a first portion ofa self-engaging fastener. For example, the self-engaging fastener mayinclude one of a hook-type fastener and a loop-type fastener.

The cutting block and the seal head may secure the fastening material tothe substrate using at least one of ultrasonic welding and an adhesive.

A method of applying a fastening material to a substrate is provided andmay include feeding the substrate in a first direction, whereby thesubstrate defines a first length extending perpendicular to the firstdirection from a first edge to a second edge. The method mayadditionally include feeding the fastening material in a seconddirection substantially parallel to the first direction, whereby thefastening material defines a second length that extends perpendicular tothe second direction and is substantially equal to the first length. Aportion of the fastening material defining a length substantially equalto the first length may be removed. The portion of the fasteningmaterial may be secured to the substrate such that the portion extendsfrom the first edge to the second edge.

In one configuration, feeding the substrate in the first direction mayinclude rotating a first material source about a first axis of rotationand feeding the fastening material in the second direction includesrotating a second material source about a second axis of rotation thatis substantially parallel to the first axis.

Removing the portion of the fastening material may include cutting thefastening material with a cutting mechanism that has a length greaterthan or equal to the first length of the substrate.

In one configuration, securing the portion of the fastening material tothe substrate may include ultrasonically welding the fastening materialto the substrate.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected configurations and not all possible implementations, and arenot intended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of a system for applying a fasteningmaterial to a substrate in accordance with the principles of the presentdisclosure;

FIG. 2 is a top view of the system of FIG. 1;

FIG. 3A is a side view of the system of FIG. 1 in a first stage ofoperation;

FIG. 3B is a side view of the system of FIG. 1 in a second stage ofoperation;

FIG. 3C is a side view of the system of FIG. 1 in a third stage ofoperation;

FIG. 3D is a side view of the system of FIG. 1 in a fourth stage ofoperation; and

FIG. 4 is a perspective view of a package formed by the system of FIG.1.

Corresponding reference numerals indicate corresponding parts throughoutthe drawings.

DETAILED DESCRIPTION

Example configurations will now be described more fully with referenceto the accompanying drawings. Example configurations are provided sothat this disclosure will be thorough, and will fully convey the scopeof the disclosure to those of ordinary skill in the art. Specificdetails are set forth such as examples of specific components, devices,and methods, to provide a thorough understanding of configurations ofthe present disclosure. It will be apparent to those of ordinary skillin the art that specific details need not be employed, that exampleconfigurations may be embodied in many different forms, and that thespecific details and the example configurations should not be construedto limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particularexemplary configurations only and is not intended to be limiting. Asused herein, the singular articles “a,” “an,” and “the” may be intendedto include the plural forms as well, unless the context clearlyindicates otherwise. The terms “comprises,” “comprising,” “including,”and “having,” are inclusive and therefore specify the presence offeatures, steps, operations, elements, and/or components, but do notpreclude the presence or addition of one or more other features, steps,operations, elements, components, and/or groups thereof. The methodsteps, processes, and operations described herein are not to beconstrued as necessarily requiring their performance in the particularorder discussed or illustrated, unless specifically identified as anorder of performance. Additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” “attached to,” or “coupled to” another element or layer,it may be directly on, engaged, connected, attached, or coupled to theother element or layer, or intervening elements or layers may bepresent. In contrast, when an element is referred to as being “directlyon,” “directly engaged to,” “directly connected to,” “directly attachedto,” or “directly coupled to” another element or layer, there may be nointervening elements or layers present. Other words used to describe therelationship between elements should be interpreted in a like fashion(e.g., “between” versus “directly between,” “adjacent” versus “directlyadjacent,” etc.). As used herein, the term “and/or” includes any and allcombinations of one or more of the associated listed items.

The terms first, second, third, etc. may be used herein to describevarious elements, components, regions, layers and/or sections. Theseelements, components, regions, layers and/or sections should not belimited by these terms. These terms may be only used to distinguish oneelement, component, region, layer or section from another region, layeror section. Terms such as “first,” “second,” and other numerical termsdo not imply a sequence or order unless clearly indicated by thecontext. Thus, a first element, component, region, layer or sectiondiscussed below could be termed a second element, component, region,layer or section without departing from the teachings of the exampleconfigurations.

With reference to FIGS. 1-3D, a package assembly system 10 is providedand may include a first material source 12, a second material source 14,and an applicator system 16. As will be described in more detail below,the package assembly system 10 may be configured to produce a package 18(FIG. 4) from the first material source 12 and the second materialsource 14. For example, the package 18 may be a container such as aplastic bag or pouch used to store various items such as foodstuffs, forexample. In this regard the package 18 may include an opening 20extending along a width W1 of the package 18. In this regard, the widthW1 may extend from a first sealed seam 22 to a second sealed seam 23opposite, and/or extending substantially parallel to, the first sealedseam 22. In some configurations, the package 18 may be a re-closablepackage, such that an end user can selectively open and close theopening 20. For example, material from the second material source 14 maybe applied proximate to the opening 20, and along the width W1 of thepackage 18, such that the end user can open and reclose the opening 20by engaging the material from the second material source 14 with atleast one of the material from the first material source 12 and amaterial from a third material source (not shown). In someconfigurations, the material from the second material source 12 may becoupled to a mating material from the third material source in order toclose and reclose the opening 20.

The first material source 12 may include a first material 24 forming apolymer substrate. For example, and in some configurations, the firstmaterial 24 may include a polyolefin substrate. The first material 24may define a length L1 extending from a first lateral edge 25 to asecond lateral edge 27 opposite the first lateral edge 25. The length L1may correspond to the width W1 of the package 18. For example, thelength L1 of the first material 24 may be substantially equal to thewidth W1 of the package 18. In this regard, the first lateral edge 25 ofthe first material 24 may correspond to the first sealed seam 22 of thepackage 18, and the second lateral edge 27 of the first material 24 maycorrespond to the second sealed seam 23 of the package 18, such that theopening 20 of the package 18 extends in a direction corresponding to thelength L1 of the first material 24.

The first material 24 may be disposed on or within the first materialsource 12 in a variety of configurations. For example, in someconfigurations, the first material source 12 may include a roll 26 ofthe first material 24. In this regard, the length L1 of the firstmaterial 24 may correspond to the length of the roll 26. In otherconfigurations, the first material source 12 may include a stack, pile,or other suitable arrangement of the first material 24, such that thelength L1 of the first material 24 corresponds to a length of thearrangement of the first material 24 within the first material source 12(i.e., a stack of the first material 24 would have a length L1).

As described, the first material source 12 may feed the first material24 from the first material source 12 in a first feed direction FD1. Asillustrated in FIG. 2, the first feed direction FD1 may be transverse tothe length L1 of the first material 24. For example, the first feeddirection FD1 may be substantially orthogonal (+/−5 degrees) to thelength L1. As previously described, in some configurations, the firstmaterial 24 may be disposed on the roll 26. Accordingly, the firstmaterial 24 may be fed in the first feed direction FD1 by rotating theroll 26 about a first axis of rotation A1. As illustrated in FIG. 2, thefirst axis of rotation A1 may be generally parallel (+/−5 degrees) tothe length L1 of the first material 24 and generally orthogonal (+/−5degrees) to the first feed direction FD1.

The second material source 14 may include a second material 30. Thesecond material 30 may include any variety of suitable fasteningmaterial. In some configurations, the second material 30 may include aself-engaging fastener 32 that is configured to mate with asimilarly-styled self-engaging fastener (not shown). While the secondmaterial 30 is shown and described herein as including a hook-shaped,self-engaging fastener 32, configured to mate with a similarhook-shaped, self-engaging fastener, the second material 30 may includeother types of self-engaging fasteners within the scope of the presentdisclosure. For example, the second material 30 may include aloop-shaped, self-engaging fastener, a mushroom-shaped self-engagingfastener, or a zipper-type self-engaging fastener. In this regard, insome configurations the second material 30 may include any form ofVELCRO® self-engaging fastener sold by Velcro USA, Inc.

The second material 30 may define a length L2 extending from a firstlateral edge 31 to a second lateral edge 33 opposite the first lateraledge 31. The length L2 may correspond to the width W1 of the package 18.For example, the length L2 of the second material 30 may besubstantially equal to the width W1 of the package 18. In this regard,the length L2 of the second material 30 may be substantially equal(+/−10%) to the length L1 of the first material 24. The opening 20 ofthe package 18 may extend in a direction corresponding to the length L2of the second material 30.

The second material 30 may be disposed on or within the second materialsource 14 in a variety of configurations. For example, in someconfigurations, the second material source 14 may include a roll 34 ofthe second material 30. In this regard, the length L2 of the secondmaterial 30 may correspond to the length of the roll 34. Accordingly,the length of the roll 34 of second material 30 may be substantiallyequal to the length of the roll 26 of first material 24. In otherconfigurations, the second material source 14 may include a stack, pile,or other suitable arrangement of the second material 30, such that thelength L2 of the second material 30 corresponds to a length of thearrangement of the second material 30 within the second material source14 (i.e., a stack of the second material 30 would have a length L2).

As described, the second material source 14 may feed the second material30 from the second material source 14 in a second feed direction FD2. Asillustrated in FIG. 2, the second feed direction FD2 may be transverseto the length L2 of the second material 26. For example, the second feeddirection FD2 may be substantially orthogonal (+/−5 degrees) to thelength L2. In this regard, the second feed direction FD2 may besubstantially parallel to the first feed direction FD1. As previouslydescribed, in some configurations, the second material 30 may bedisposed on the roll 34. Accordingly, the second material 30 may be fedin the second feed direction FD2 by rotating the roll 34 about a secondaxis of rotation A2. As illustrated in FIG. 2, the second axis ofrotation A2 may be generally parallel (+/−5 degrees) to the length L2 ofthe second material 30 and generally orthogonal (+/−5 degrees) to thesecond feed direction FD2.

The applicator system 16 may include a cutting block 40, a seal head 42,and a drive mechanism 44. As will be explained in more detail below, theapplicator system 16 may be configured to remove a portion 46 (FIGS.3B-4) of the second material 30 and apply the portion 46 of the secondmaterial 30 to the first material 24.

The cutting block 40 may include coupling mechanism 48 and a cuttingmechanism 50. The coupling mechanism 48 may include any variety ofmechanism configured to engage and selectively secure the secondmaterial 30. For example, the attachment mechanism 48 may include anadhesive, a suction source, or a mechanical fastener(s) that engages andsecures the second material 30 to the cutting block 40. In someconfigurations, the coupling mechanism 48 may include a self-engagingfastener (not shown) that engages the self-engaging fastener 32 of thesecond material 30.

The cutting mechanism 50 may include a blade 54 that selectively engagesand cuts the second material 30. As illustrated in FIG. 2, the blade 54may define a length L3 extending from a proximal end 56 to a distal end58. In this regard, the blade 54 may extend in a direction substantiallyperpendicular to the first and second lateral edges 25, 27 of the firstmaterial 24, and generally parallel to the opening 20 of the package 18.The length L3 may be equal to or greater than the length L1 of the firstmaterial 24 and the length L2 of the second material 30.

The seal head 42 may selectively engage the first material 24. Asillustrated in FIG. 2, the seal head 42 may define a length L4 extendingfrom a proximal end 57 to a distal end 59. In this regard, the seal head42 may extend in a direction substantially perpendicular to the firstand second lateral edges 25, 27 of the first material 24, and generallyparallel to the opening 20 of the package 18. The length L4 may be equalto or greater than the length L1 of the first material 24 and the lengthL2 of the second material 30.

As illustrated in FIGS. 3A-3D, the drive mechanism 44 may include anyvariety of drive mechanism that translates the cutting block 40 in afirst direction D1 and/or a second direction D2. Additionally oralternatively, the drive mechanism 44 may translate the seal head 42 inthe first direction D1 and/or a third direction D3. For example, thedrive mechanism 44 may include a gear train, a belt-drive system, or ahydraulic drive mechanism (none shown) that translates the cutting block40 and/or the seal head 42 in one or more of the first, second, andthird directions D1, D2, D2. In particular, the drive mechanism 44 maytranslate the cutting block 40 and/or the seal head 42 toward the firstand/or second materials 24, 30. In this regard, the first direction D1may be substantially parallel to the first and second feed directionsFD1, FD2, and the second and third directions D2, D3 may besubstantially perpendicular to the first and second feed directions FD1,FD2.

With reference to FIGS. 3A-3D, a method of applying the second material30 to the first material 24 will now be described. As illustrated inFIG. 3A, the method may include feeding the first and/or secondmaterials 24, 30 in the first and second feed directions FD1, FD2,respectively. In this regard, the first stage of operation may includerotating the first roll 26 about the first axis of rotation A1 and/orrotating the second roll 34 about the second axis of rotation A2.

With reference to FIG. 3B, the method may also include translating thecutting block 40 relative to the second material 30 and/or translatingthe seal head 42 relative to the first material 30. For example, themethod may include translating the cutting block 40 in the first and/orsecond directions D1, D2, and/or translating the seal head 42 in thefirst and/or third directions D1, D3. In particular, the method mayinclude translating the cutting block 40 in the second direction D2 suchthat the blade 54 engages and cuts the second material 30 and thecoupling mechanism 48 engages and secures the second material 30. Inthis regard, the coupling mechanism 48 may engage and secure the portion46 of the second material 30. As illustrated in FIG. 2, the portion 46may include a length L5 extending from a first lateral edge 60 to asecond lateral edge 62 opposite the first lateral edge 60, and a widthW2 extending from a proximal end 64 to a distal end 66 opposite theproximal end 64. Relative to the package 18, the width W2 may extend ina direction substantially perpendicular to the opening 20 of the package18, and substantially parallel to the first and second sealed seams 22,23 of the package 18. The length L5 may be substantially equal to thelength L1 of the first material 24. In this regard, the length L5 may besubstantially equal to the width W1 of the opening 20 of the package 18.The width W2 of the portion 46 may be between 1% and 10% of the lengthL5 of the portion. In some configurations, the width W2 may besubstantially equal to 5% of the length L5.

As illustrated in FIG. 3C, the method may also include translating thecutting block 40, including the portion 46 of the second material 30,relative to the first material 24. For example, the method may includetranslating the cutting block 40 in the first and/or second directionsD1, D2 and may further include placing the portion 46 of the secondmaterial 30 into engagement with the first material 24. In this regard,the method may include engaging the portion 46 with a first side 70 ofthe first material 24 and engaging the seal head 42 with a second side72 of the first material 24, where the first side 70 is opposite thesecond side 72. Accordingly, the first material 24 and the portion 46 ofthe second material 30 may be clamped by and disposed between thecutting block 40 and the seal head 42.

The method may also include securing the portion 46 of the secondmaterial 30 relative to the first material 24. For example, the methodmay include fastening the portion 46 to the first material 24 using oneor more of a variety of techniques. In some configurations, the methodmay include transmitting ultrasonic wave energy into one or both of theportion 46 and the first material 24 through one or both of the cuttingblock 40 and the seal head 42 in order to ultrasonically weld the firstmaterial 24 to the portion 46. In other configurations, the method mayinclude activating an adhesive by applying heat to one or both of theportion 46 and the first material 24 through one or both of the cuttingblock 40 and the seal head 42 in order to fasten the first material 24to the portion 46.

With reference to FIG. 3D, upon securing the portion 46 to the firstmaterial, the method may include translating the cutting block 40relative to the second material 30 and/or translating the seal head 42relative to the first material 30. For example, the method may includetranslating the cutting block 40 in a direction opposite the firstand/or second directions D1, D2, and/or translating the seal head 42 ina direction opposite the first and/or third directions D1, D3. Inparticular, the method may include translating the cutting block 40toward the second material source 14 and/or translating the seal head 42toward the first material source 12.

With reference to FIG. 4, the method may also include securing a thirdmaterial 76 to the first material 24. For example, the method mayinclude securing the third material 76 to the first material 24 alongone or more of the first lateral edge 25, the second lateral edge 27,and a bottom edge 78 of the first material 24, to form the first sealedseam 22, the second sealed seam 23, and a third sealed seam 80,respectively, of the package 18. In this regard, the opening 20 of thepackage 18, and the width W2 of the portion 46 of the second material30, may extend in a direction substantially parallel to the third sealedseam 80, and substantially perpendicular to the first and second sealedseams 22, 23. While not specifically shown, the third material 76 maysimilarly receive a portion of a fastener that mates with the secondmaterial 30. For example, if the second material 30 is a hook-typefastener, a loop-type fastener may be applied to the third material 76to allow the loop-type fastener to engage the hook-type fastener toallow a user to selectively reclose the opening 20 of the package 18.The loop-type fastener may be applied to the third material 76 using theprocess described above for attaching the hook-type fastener (i.e., thesecond material 30) to the first material 24. While the first material24 is described as receiving a hook-type fastener and the third material76 is described as receiving a loop-type fastener, the first material 24could alternatively receive the loop-type fastener and the thirdmaterial 76 could receive the hook-type fastener.

By cutting the second material 32 such that the portion 46 has a widthW2 and a length L5 extending in the directions and having theproportions described, the system 10 and method described herein areable to greatly reduce the amount of time required to manufacture thepackage 18. For example, by measuring a width W2 of the portion 46 thatis less than the length L5 and that extends in a direction substantiallyparallel to the first and second lateral edges 25, 27 of the firstmaterial 24, the system 10 and corresponding method are able to rapidlymanufacture the package 18. That is, for example, the methods andsystems of the present application define an index or metering length inthe direction FD2 of the fastening material 30 off the second materialsource 14 that is the width W2 of the portion 46. In some approaches,this metering length is about 0.25 to about 1 inch long, and in otherapproaches, about 0.25 to about 0.5 inches long. This is in contrast toprior systems that required metering the entire length L2 of thefastener material in a direction transverse to the feed directions ofthe package substrate. In other approaches, the systems and materialsherein enable the fastening material 32 to be flangeless or free of anyflanges (or other areas of non-fastening material-that is materialwithout hook and loop type fasteners, for instance) on opposing sides ofthe cut fastener portion 46.

The foregoing description has been provided for purposes of illustrationand description. It is not intended to be exhaustive or to limit thedisclosure. Individual elements or features of a particularconfiguration are generally not limited to that particularconfiguration, but, where applicable, are interchangeable and can beused in a selected configuration, even if not specifically shown ordescribed. The same may also be varied in many ways. Such variations arenot to be regarded as a departure from the disclosure, and all suchmodifications are intended to be included within the scope of thedisclosure.

What is claimed is:
 1. A system for applying a fastening material to asubstrate, the system comprising: a first material source including thesubstrate, the substrate defining a first length extending from a firstedge to a second edge, the first material source configured to feed thesubstrate in a first direction transverse to the first length; a secondmaterial source including the fastening material, the fastening materialdefining a second length extending from a third edge to a fourth edge,the second length substantially equal to the first length, the secondmaterial source configured to feed the fastening material in a seconddirection transverse to the second length; and an applicator systemhaving a cutting block and a seal head, the cutting block having acutting mechanism defining a third length substantially equal to thefirst length, the seal head defining a fourth length substantially equalto the first length, the cutting block and the seal head configured tosecure the fastening material to the substrate such that the first edgeis aligned with the third edge and the second edge is aligned with thefourth edge.
 2. The system of claim 1, wherein the first material sourceincludes a first axis of rotation and the second material sourceincludes a second axis of rotation, the first length extending in adirection substantially parallel to the first axis of rotation, thesecond length extending in a direction substantially parallel to thesecond axis of rotation.
 3. The system of claim 1, wherein the fasteningmaterial defines a width extending in a direction perpendicular to thesecond length, the width being less than the second length.
 4. Thesystem of claim 3, wherein the width is between 1% and 10% of the secondlength.
 5. The system of claim 1, wherein the fastening materialincludes a first portion of a self-engaging fastener.
 6. The system ofclaim 5, wherein the self-engaging fastener includes one of a hook-typefastener and a loop-type fastener.
 7. The system of claim 1, wherein thecutting block and the seal head are configured to secure the fasteningmaterial to the substrate using at least one of ultrasonic welding andan adhesive.
 8. A method of applying a fastening material to asubstrate, the method comprising: feeding the substrate in a firstdirection, the substrate defining a first length extending perpendicularto the first direction from a first edge to a second edge; feeding thefastening material in a second direction substantially parallel to thefirst direction, the fastening material defining a second lengthextending perpendicular to the second direction, the second lengthsubstantially equal to the first length; removing a portion of thefastening material, the portion defining a length substantially equal tothe first length; and securing the portion of the fastening material tothe substrate such that the portion extends from the first edge to thesecond edge.
 9. The method of claim 8, wherein feeding the substrate inthe first direction includes rotating a first material source about afirst axis of rotation, and wherein feeding the fastening material inthe second direction includes rotating a second material source about asecond axis of rotation, the second axis being substantially parallel tothe first axis.
 10. The method of claim 8, wherein removing the portionof the fastening material includes cutting the fastening material with acutting mechanism, the cutting mechanism having a length greater than orequal to the first length of the substrate.
 11. The method of claim 8,wherein securing the portion of the fastening material to the substrateincludes ultrasonically welding the fastening material to the substrate.